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Audi A2 Intake Manifold Problem

  • 12-07-2012 2:55pm
    #1
    Tropheus
    Registered Users, Registered Users 2 Posts: 1,947 ✭✭✭


    My wife's 2003 A2 1.6 FSI Sport has been running well of late. However, the Check Engine Light came on last night and it's throwing up the following codes:

    17428 - Fuel Pressure Regulation Control Range Exceeded
    P1020 - 35-10 - - - Intermittent
    17412 - Torque Difference Cylinder 1 Limit Value Exceeded
    P1004 - 35-00 - -
    17912 - Intake Air System: Leak Detected
    P1504 - 35-10 - - - Intermittent
    18043 - Powertrain Data Bus: Missing Message from A/C Controller
    P1635 - 35-10 - - - Intermittent
    17439 - Manifold Change-Over Valve (N136): Setpoint Not Reached
    P1031 - 35-00 - -

    I did a search and I'm pretty sure it's all related to the intake manifold flap. I had a look this evening and the plastic arm from the vacuum actuator that sits above it is broken. It's a common problem on the A2 1.6 FSI.

    Would I be safe in assuming that the potentiometer (intake flap mechanism) is also knackered? I'm assuming that it jammed and caused the arm on the actuator to break.

    It looks like a very big job to remove the intake manifold to get at the potentiometer - especially in the A2 as there's not much space. There's an air scoop that sits above the manifold that would need to be removed which looks like it involves removing the wipers and motor.:(

    I had a look around, but there's not much details on the steps involved bar quotes for huge main dealer repairs. I believe this is a relatively common problem on the 1.6 BAD engine which is also fitted to the Golf amongst other models in the VAG range.

    I would consider doing this myself if I had more details. Parts are around €90 for the actuator and €60 for the flap mechanism. I've heard some people had to replace the intake manifold itself due to carbon build up. I hope not in my case as that's about €400.

    Has anyone had to do this before?


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